Mechanical Engineer (Plastics Components Design, V&V, Inspection & Test Plan)

Must Have: Plastic component design Test Plan, , ITP (Inspection & Test Plan

Key Responsibilities

• Conduct research to explore emerging technologies, materials, and engineering methodologies. Identify opportunities for innovation by proposing new design concepts or enhancing existing products to meet evolving customer and industry requirements.
• Design mechanical systems, components, and assemblies with a strong emphasis on manufacturability, cost-efficiency, and performance. Utilize advanced CAD software for 2D drafting and 3D solid modeling to develop detailed part and assembly designs.
• Demonstrate expertise in the design of plastic components. Incorporate best practices for injection molding, such as appropriate wall thickness, uniform material distribution, draft angles, undercuts, ribs, bosses, and snap-fits to ensure moldability, structural integrity, and cost-effective manufacturing.
• Collaborate with toolmakers and molding vendors during the design phase to address DFM (Design for Manufacturability) and DFA (Design for Assembly) requirements. Apply GD&T standards to ensure accurate part tolerancing for plastic parts and assemblies.
• Create physical and digital prototypes of mechanical designs, especially for plastic parts where early validation is critical to assess structural performance, fit, form, and function. Work iteratively to refine design based on feedback from prototyping, simulation, and stakeholder inputs.
• Develop and execute comprehensive validation and verification (V&V) test plans to ensure that prototypes and final designs meet all project requirements, performance benchmarks, and regulatory standards. This includes conducting in-house tests (e.g., drop, thermal, vibration, fatigue, and material property tests), as well as coordinating with external accredited test labs or vendors for specialized testing when needed.
• When required, design custom test setups or fixtures to validate unique design aspects, particularly for plastic mechanisms or assemblies involving tight tolerances or complex motion.
• Analyze test results, identify root causes of failure or deviation, and drive design iterations using data-driven decision-making to optimize product performance, durability, and safety.
• Identify and troubleshoot mechanical design issues, proposing innovative and manufacturable solutions that align with project goals and timelines.
• Work closely with other teams, including design, manufacturing, and marketing, to ensure the practical application of new innovations and facilitate the transition of designs into production.
• Prepare and maintain complete engineering documentation such as design specifications, 3D models, 2D drawings, BOMs, test protocols, validation reports, and engineering change records, ensuring traceability and compliance with product development processes.